Papers by Keyword: Mould Filling

Abstract: This article is about casting process of tensioner pulley bracket, which includes solidification simulation, mould filling simulation and defect forecast, using ViewCast software. The scale and location of the shrinkage defects were shown in simulation results. Solidification results demonstrated that the casting defects were not eliminated by the casting technology. The optimized scheme was obtained by replacing and adding chills. The optimization scheme was calculated and the simulation results shown that the reasonable casting process was obtained and the process has been proofed by the productive practice.

Abstract: A three-dimensional Computer Aided Design (CAD) model of the mould clamping board is established by Pro/E software. The ViewCast program is utilized to study casting processes of solidification and mould-filling in order to design the risers and optimize the casting technology. Based on the solidification simulation, the casting defects such as shrinkage and porosity are forecasted visually in diagrams with the help of ViewCast. Reasonable risers are designed on the basis of the solidification simulation. The mould-filling simulation verify the metal fluid gates the mould smoothly and reposefully. The filling simulation results of initial casting scheme show that this casting technology is improper. The optimized scheme is completed through the filling simulation and a modified casting technology is obtained. The parting gating system is used to pouring the mold of clamping board. The simulation results of optimized scheme indicate that the shrinkage are eliminated effectively and the metal fluid fill the mold smoothly. Experimentally, the casting confirms that the optimized method is very useful in reducing the casting defects and improving the product quality.

Abstract: The apparent viscosity model of the semi-solid A356 aluminum alloy, based on fitting of experimental data obtained by the Couette type viscometer, was developed in the paper. The commercial package CastSoft6.0 coupled with the model was used to simulate the mould filling of the semi-solid A356 aluminum alloy in the key-shaped component with iron cores. The simulation results showed that the position of the iron cores has an important effect on the filling of the semisolid slurry, and it is easy to obtain the completely filled key-shaped component when the iron cores were near to the inlet. The filling tests verified that the simulation results have good agreement with the experimental results. The fitting results indicated that the developed apparent viscosity model is practical and feasible and it can be used to simulate the mould filling process of the semisolid A356 aluminum alloy slurry. Also the parameters were optimized and the optimum parameters are as follows: the inject pressure is more than 15MPa, the inlet velocity is more than 1.73m/s and the forming temperature is over 585 °C.